Toy forming apparatus



J. W. RYAN ETAL April 27, 1965 TOY FORMING APPARATUS l0 Sheets-Sheet 1Filed Feb. 8, 1965 INVENTORS z/fl/V/l/ 14/ FJ A/V BY 4001/ 5 GOZDFAIQEApnl 27, 1965 J. w. RYAN ETAL 3,179,980 TOY FORMING APPARATUS Filed Feb.8, 1963 10 Sheets-Sheet 2 A ril 27, J. w. RYAN ETAL TOY FORMINGAPPARATUS l0 Sheets-Sheet 3 Filed Feb. 8, 1963 $0 5 M W T 0 \Q Iw M i KW, i m k MW 1w m ya $1 m M m --..imllllllllllllllll K [M m Ap 1965 J. w.RYAN ETAL TOY FORMING APPARATUS l0 Sheets-Sheet 4 Filed Feb. 8, 1963 Aril 27, 1965 J. w. RYAN ETAL 3,179,980

TOY FORMING APPARATUS Filed Feb. 8, 1963 10 Sheets-Sheet 5 ATTOF April1965 J. w. RYAN ETAL TOY FORMING APPARATUS l0 Sheets-Sheet 6 Filed Feb.8, 1965 April 27, 1965 J. w. RYAN ETAL TOY FORMING APPARATUS l0Sheets-Sheet 7 Filed Feb. 8, 1963 INVENTORS JJ/V/l/ M! 74 BY AOUZPH 1G'OZDFAPE WwWr A ril 27, 1965 J. w. RYAN ETAL TOY FORMING APPARATUS l0Sheets-Sheet 8 Filed Feb. 8, 1965 IN VENTOR5 067V W [FL 4N Apr i127,1965 J. w. RYAN ETAL TOY FORMING APPARATUS l0 Sheets-Sheet 9 Filed Feb.8, 1963.

April 27, 1965 J. w. RYAN ETAL 3,179,980

TOY FORMING APPARATUS Filed Feb. 8, 1963 10 Sheets-Sheet 10 INVENTORSJay/v M fik/M/ BY AQUZPH .5 6010/5425 United States Patent M 3,179,980TGY FGRMING APPARATUS John W. Ryan, Bel Air, and Adolph E. Goldfarb,North Hollywood, Calif., assignors to Mattel, Inc., Hawthorne, Caliii, acorporation of California Filled Feb. 8, 1963, Ser. No. 257,129 Claims.(Cl. 1819) The present invention relates generally to a toy formingapparatus and more particularly to a novel and improved form of such anapparatus whereby a thermo plastic sheet is softened by heat and thenformed into a desired shape by the application of a pressuredifferential.

There have been various commercial installations for the practice of theprocess generally known as vacuum forming. This process entailsgenerally subjecting a sheet of thermoplastic material to a heat sourceto soften and make the thermoplastic sheet pliable and workable. Afterthe sheet is thus softened, a pressure differential between the twosides of the sheet is created as by inducing a vacuum on the side of thesheet adjacent a mold which causes the sheet to adhere to the form ofthe mold. Then when the sheet is allowed to cool it will retain itsnewly assumed shape to provide an object which is a reproduction of themold. In commercial operation, however, it is necessary that thisoperation be conducted on a large scale and continuous basis with thesheet being heated rapidly, formed rapidly and then cooled rapidly tomake way for the next sheet. Time is a prime consideration and thereforerather complicated and expensive equipment is utilized at the commerciallevel to provide rapid, reliable and often automatic operation. Further,to provide quick action, a high level heat source is often used in suchapparatus.

The utilization of this general method in a toy apparatus for use byeven small children obviously involves a number of difficulties.Initially, the toy must be relatively simple in construction andoperation to enable small children to operate it. Further, it must berelatively simple and inexpensive to construct, so as to make itcommercially feasible to produce and sell this item as a toy at areasonable cost. Further, care must be taken to make the toy apparatussafe for use by small children.

Various more specific problems present themselves. There is a need for asimple, yet effective holder or clamping device to hold the plasticsheet during the various operations. This holding means must besufficiently simple in operation so that it may be used by smallchildren. At the same time it must be effective in securely holding thethermoplastic sheet securely and firmly while the sheet undergoes firstthe heating and softening operation and subsequently the formingoperation. It is also desired that this holding means be readily andsimply released when the sheet has been formed so that a new sheet mayreplace it. There are also problems incident to providing an eifectiveseal for the area in which the pressure is to be reduced. There are alsovarious other problems relating to heat dissipation and distribution.

Accordingly, it is a principal object of the present invention toprovide a novel and improved toy forming apparatus.

It is another object to provide such a toy forming apparatus having asimple, yet effective holding means for securely, yet releasably holdinga thermoplastic sheet during the operation of the apparatus.

Another object is the provision in a toy forming apparatus of releasableyet positive physical connection between the holding means and thethermoplastic sheet.

Still another object is the provision of holder means comprising a pairof interlocking holding frame members incorporating novelinterconnection means therebetween.

Another object is the provision of an improved thermo- 3,17%,989Patented Apr. 27, 1965 plastic sheet construction for use with such atoy forming apparatus.

A further object of the present invention is the provision of animproved toy forming apparatus in which improved means are provided forcontrolling the flow and distribution of heat to the parts of theforming apparatus adjacent to the thermoplastic sheet during the heatingoperation.

Still another object of the present invention is the provision of animproved toy forming apparatus, having means for forming an efiectiveseal for the reduced pressure compartment of the apparatus.

Still a further object of the present invention is to provide a toyforming apparatus having improved means for producing a pressuredifferential.

It is also an object of the present invention to provide a simple andinexpensive device which is also sturdy, durable and effective. 7

Various other objects and advantages of the present invention willbecome obvious from the following description and from the accompanyingdrawings, wherein:

FIGURE 1 is a perspective view of a toy former embodying the variousfeatures of the present invention with such toy former positioned readyto initiate its operation.

FIGURE 2 is a perspective view of the toy former of FIG. 1 with itsparts positioned to perform the heating portion of its operation.

FIGURE 3 is a perspective View of the toy former of FIG. 1 showing itsparts positioned to perform the forming portion of its operation.

FIGURE 4 is a top view of the toy former positioned as shown in FIG. 2with portions of the apparatus broken away to show details of theconstruction.

FIGURE 5 is a cross-sectional view of FIG. 4 taken along the line 55 ofFIG. 4.

FIGURE 6 is an end view of FIG. 5 taken along the line 6-6 of FIG. 5.

FIGURE 7 is a cross-sectional view of FIG. 5 taken along the lines 77 ofFIG. 5.

FIGURE 8 is a cross-sectional view of FIG. 5 taken along the lines 8-3of FIG. 5.

FIGURE 9 is a cross-sectional view of FIG. 8 taken along the lines 99 ofFIG. 8.

FIGURE 10 is a cross-sectional view of FIG. 8 taken along the linesIii-16 of FIG. 8.

FIGURE 11 is a cross-sectional view of FIG. 3 taken along the lines11-11 of FIG. 3.

FIGURE 12 is a cross-sectional view of FIG. 11 taken along the linesl2-li2 of FIG. 11.

FIGURE 13 is a cross-sectional view of FIG. 11 taken along the lines1313 of FIG. 11.

FIGURE 14 is a perspective view of the thermoplastic sheet utilized inthe present invention.

FIGURE 15 is a cross-sectional view of FIG. 14 taken along the lines15-15 of FIG. 14 showing the orientation of the sheet with reference tothe heating element of the toy former.

FIGURE 16 shows the thermoplastic sheet after it has been molded.

FIGURE 17 is a cross-sectional view along the lines I717 of FIG. 4.

FIGURE 18 is a cross-sectional view of FIG. 4 taken along the lines 1818of FIG. 4.

FIGURE 19 is an enlarged view of a detail of the corner of the housing.

FIGURE 20 is a cross-sectional view of FIG. 5 taken along the lines 20-20 of FIG. 5.

FIGURE 21 is an exploded perspective view of another embodiment of themold of the present invention.

FIGURE 22 is a perspective view of another embodiment of the cap memberelement of the mold shown in FIG. 21.

FIGURE 23 is an exploded perspective view of the of FIG. 4 taken avehicle body formed by the mold of FIG. 21 showing is relation to theother portions of the vehicle.

FIGURE 24 is a perspective view of another embodiment of the cap member,hood member and side panel elements of the mold shown in FIG. 21.

FIGURE 25 is a perspective view of still another embodiment of the capmember and hood member elements of the mold shown in FIG. 21.

FIGURE 26 is a perspective view of still another embodiment of thecombined cap and hood member elements of the mold shown in FIG. 21.

Briefly, the illustrated toy forming apparatus 30 is adapted to form anobject 32 from a sheet 34 of thermoplastic material by applying heat tothe sheet of material and subjecting the sheet to a pressuredifferential. The illustrated apparatus '39 includes a housing 36 whichpartially encloses a heating station means 38 and a forming stationmeans 40. The illustrated toy 30 further includes an open-center holdingframe means 42 for releasably holding the thermoplastic sheet 34 and atransfer or lever means 44 for moving the holding frame means 42 withsheet 34 between the heating station means 38 and the forming stationmeans 40.

The sheet 34 is heated first at the heating station means 38 to make itsoft and workable and it is then moved by the transfer means 44 to theforming station means 46 where it is positioned down over a mold havingthe shape of the object 32 on which the sheet is to be formed. The sheet'34, the holding frame means 42 and the forming station means 40 combineto define a substantially sealed compartment or area 47 (FIGURE 11). Thetoy apparatus also is provided with means 49 for reducing the pressurein the compartment 47, thus causing the softened thermoplastic sheet tobe formed or shaped to the outline of the mold 45.

The illustrated holding frame means 42 includes a first or loweropen-center holding frame member 46 and a second or upper open-centerholding frame member 48 which interconnect to releasably, yet securely,hold the periphery of the thermoplastic sheet 34 during the variousoperations of the apparatus 30. In the illustrated toy apparatus 30 thefirst holder frame member 46 is provided with locating and holding meansin the form of a plurality of projections 50 which are adapted to engagea matching plurality of apertures 52, extending along substantially theentire periphery of the thermoplastic sheet 34. When the two holdingframe members 46 and 48 are secured together with the projections 50extending through the apertures 52 in the thermoplastic sheet, the sheetis securely held along its entire periphery against forces tending todistort or warp the sheet. The interaction of the two holder framemembers serves to prevent the sheet from disengaging from theprojections 50.

In the illustrated toy forming apparatus 30, the upper holding framemember 48 is constructed of metal connected to the upper holding framemember 48 and of the same material, is a pair of resilient flexibledetent elements 54 which engage receptacle or reception means 56 on thelower holding frame member 46. Thus, the detent elements 54 and thereception means 56 provide interconnection means 58 (FIGURE 7) wherebythe two holding frame members are held in locked but releasableengagement. In the illustrated toy apparatus 30, the reception means 56is so positioned and constructed as to require flexing of the flexibledetent element 54 incident to the engagement and disengagement of theelement 54 with the reception means 56.

In addition, the illustrated toy 30 is provided with heat distributingand dissipating means 60 which serves to maintain the parts of the toyapparatus '30 surrounding the thermoplastic sheet 34 relatively coolwhile the sheet is being heated by a suitable heating means 62 carriedwithin the illustrated housing 36.

The illustrated toy forming apparatus 30 is also usable to particularadvantage with the thermoplastic sheet 34 4 such as shown in thedrawings which comprise a film 64 having a metallic layer 66 atfixed toit to give the formed object 32 an aluminized appearance. The metalliclayer 66 is secured to the surface of film 64 remote from the surface ofthe film 64 being heated as illustrated in FIG- URE 15. The illustratedsheet 34 is further provided with a black layer 68 of lacquer or ink orother comparable material so that the thermoplastic sheet will readilyand uniformly heat as desired and reach the necessary softenedcondition.

The preferred embodiment shown in the drawings includes a perforatedplate 70 which supports the mold 45 and cooperates with the formingstation means 40 to provide for passage of air to permit effectivereduction of pressure in the volume 47 between the sheet 34 and the mold45 incident to the forming of the sheet.

Thus a highly effective, yet simple and economical toy forming apparatus30 is provided, having a variety of novel and improved features andparticulars.

Now to consider the structure of the toy forming apparatus '30 infurther detail, the apparatus includes a generally rectangular housingor frame 36 which is a generally rectangular box-like structure. Thehousing 36 includes a pair of elongated sidewalls and 82, a pair offoreshortened endwalls 84 and 36, a bottom wall 88 and an upper wall 99.In the illustrated housing 36, an upper platform 94 provides the upperwall 90 of the housing 36. The upper platform 94 is locked onto thehousing 36 by means of flanges such as flange 37 on endwall 86 beingslipped into apertures 95 in platform 94 as shown in FIGURE 17. Theplatform 94 also includes the heating station means 38, adjacent endwall84, and the forming station means 40 which are located adjacent theendwall 86.

The heating station means 38 includes a series of fins 92 and fourenlarged fins 96 supporting the holding frame means 42 when it ispositioned at the heating station as shown in FIGURE 5. The enlargedfins 96 permit the holding frame means 42 to be positioned adjoining theheating station means 38 while simultaneously permitting the fins 92 toefiiciently radiate the excess heat away from the apparatus. The open orvented and finned network which comprises the heat dispensing anddistributing means 60 serves to minimize heat transfer from the area ofthe heating station outwardly to those adjacent portions of the upperplatform wall 94.

The forming station means 40 are elevated on the structure relative tothe heating station means 38. The forming station means 40 include agenerally rectangular turret structure 97 of lesser width than the upperplatform 94 and of approximately one-half its length. The turret 97 islocated somewhat inwardly from endwall 86 of the housing 36. The turret97 includes four generally vertical sidewalls 98 and a horizontal upperor top wall 100. As seen best in FIGURES 1, 4 and 8, the upper platformwall 94 located outwardly of the turret 97 is provided with a pluralityof air vents 102, while the upper wall 100 of the turret 97 is providedwith similar arr vents 103 at its end closest to the heating station.

The forming station means 40 also include a vertical compartment Wall orfence 104, secured to the upper wall 100 and extending upwardlytherefrom. The compartment wall 194 is generally rectangular in shape,having a slightly smaller width than upper wall 100 and having lesslength than wall 100. The compartment wall 194 is located upon Walltoward its end furthest away from the heating station, thereby providingspace for the air vents 103 in the wall 100 outwardly of the compartmentWall 104.

The holding frame means 42 of the illustrated apparatus includes a loweropen-center holding frame member 46 and an upper open-center holdingframe member 48. These two members 46 and 48 are both pivoted about acommon axis designated A-A and seen best in FIGURE 4 of the drawings.The holding frame means members 46 and 48 are shown generally disposedwith their open centers over the heating station in FIGURES 2, 4 and5-7. They are shown disposed over and embracing the forming station inFIGURES 3 and 11. FIGURE 1 shows the two holding frame members 46 and 48separated from one another and pivoted somewhat relative to one another.

For convenience of description the holding frame members 46 and 43 willbe described in their respective positions over the heating stationexcept where specifically noted in another position. Of course, theframe members assume the entire spectrum of positions between that atthe heating station and that at the forming station in the course of theoperation of the apparatus wherein said frames are pivoted or tiltedbetween the two stations.

The lower holding frame member 46 is a ring or loop structure ofgenerally rectangular configuration having two vertical sidewalls 166and a pair of vertical endwalls 108. The member 46 is provided with anarrow, inwardly extending annular lower lip or flange 111) at the loweredge of the vertical walls 166 and 108. A plurality of closely spacedapart vertically extending pins or projections 50 are secured alongsubstantially the entire flange 116 and extending upwardly from theupwardly facing surface thereof. The illustrated projections 50 arearranged in aligned rows extending along each side of the frame member46.

In the illustrated structure, the projections 56 are all alike, having acircular horizontal cross-section although other shapes of cross-sectionmay be used such as triangular or rectangular. Furthemore, theprojections 50 preferably taper outwardly towards their base e.g. for acircular cross-section, they may be frusto-conical in shape; however,they may have a uniform cross-section e.g. for a circular cross-section,they may be cylindrical in shape. The illustrated lower holding framemember 46 has longer sidewalls 166 than endwalls 108. However, ifdesired, each of the walls of the frame member 46 could be equal topermit ready reception of the thermoplastic sheet 34 by the frame member46 regardless of the orientation of the sheet. also be possible toprovide particular positioning means which would further restrict orlimit the orientation of the thermoplastic sheet 14 in the frame memberand this result could be accomplished by varying the position, size orconstruction of the projections 56 as Will be readily understood as thedescription progresses. Also, if desired, the projections 56 may belocated on upper frame member 43.

As shown in FIGURES 4, 5 and 7, particularly, frame member 46 is securedat each side to an elongated side bar 116 by a pair of horizontallyextending connections 118 and 126. The illustrated side bars 116extending outwardly of and generally parallel to vertical sidewalls 106of the frame member 46 and extend beyond the frame member 46 at eitherend thereof. As shown in FIGURE 7, an annular upper lip or flange 122extends horizontally outwardly from the upper edge of each sidewall 166and then terminate in an upwardly extending annular lip or flange 123.The connections 118 and 126 at either side of the frame member 46 extendoutwardly from the upper portion of the flange 163.

The connection 118 includes a knob 118a extending from the sidewall 166of the lower frame member 46 and a pair of ribs 118!) separated by theknob 118a and attached to the side bar 116. The edges of the ribs 118badjoining the knob 118a are spaced slightly away therefrom to achieve aloose fit and thus to permit the frame member 46 to move or tiltslightly in relation to the side bar 116 while retaining a secureconnection therebetween. Such spacing may be in the range of about inchto M; inch but it is preferably about inch.

The connection 126 includes an X-shaped boss 120a extending from thesidewall 106 of the lower frame member 46 and a socket 12% attached tothe side bar 116 and On the other hand, it would into which the boss ais inserted. The socket 120]) has a rib 1200 across its base whichadjoins the end of the boss 120a. Such arrangement minimizes thefrictional resistance to movement between the lower frame member 46 andthe side bar 116. In addition, the peripheral edges of the boss 120a arespaced slightly away from the internal surfaces of the socket 1201).Thus, similar to the connection 118, the connection 120 achieves a loosefit and permits the frame member 46 to move or tilt slightly in relationto the side bar 116 while retaining a secure connection therewith. Suchspacing is preferably about to inch.

From the foregoing description it will be apparent that the workpieceholding frame is mounted for limited universal movement on its carryingstructure.

Along the lower edge of each sidewall 106 runs a small lower guideextension 124 which serves to support the frame member 46 when the framemember 46 is lowered down into the first position over the heatingstation. As seen best in FIGURE 7, the extensions 124 rest outwardly ofthe lower flange 110 of the lower holding frame member 26 upon theenlarged fins 96.

The transfer or lever means 44 include the elongated side bars 116 whichextend beyond the sidewalls 166 of the frame member 46, as noted above.At their outer ends, the side bars 116 are secured to the large handle128 which extends substantially across the width of the apparatus. Thehandle 128 is hollow with an open side formed by a thin wall 128a. Thehandle 128 is connected to the side bars 116 by the engagement ofgrooved sockets 128!) with correspondingly grooved fingers 116aextending from the side bars 116 (see FIG. 4). Such constructionminimizes heat conduction to the handle 128 from the apparatus whilepromoting heat loss by means such as free air circulation adjoining allof its surfaces.

The other ends of the side bars 116 are pivoted about line AA to thevertical sidewall 9'8 of turret 97 by means of cylindrical pivot pins126. The aperture 1161) in each of the sidebars 116 through which thepivot pin 126 extends is slightly larger in diameter than the pivot pin126 to achieve a loose fit therebetween. Thus the transfer means 44 ispermitted to universally move or tilt slightly with respect to theturret 97 while retaining a secure connection therebetween. Such spacingmay be in the range of about inch to inch.

The upper holding frame member 48 is a rectangmlar loop or ringconstructed somewhat like lower frame member 46 and is adapted to bepositioned or nest into frame member 46 in the relative position shown,for example, in FIGURE 2. Upper frame holding frame member 43 includes apair of generally vertical sidewalls 131 and a pair of generallyvertical end walls 132. While vertical walls 136 and 132 shall bereferred to as vertical, they are in fact somewhat sloped in thepreferred embodiment of the apparatus both from the standpoint of easeof fabrication and also to provide effective fit with the walls of thelower holding frame member 46 and the forming station means 40 as willbe understood from the following description.

Vertical walls and 132 have their upper portion" offset outwardlysomewhat to provide an annular external shoulder 136 for the framemember 48. This shoulder 136 may serve to engage the upper edge of thewalls 166 and 108 of lower frame member 26 when the two holding framemembers are nested together as for example shown in FIGURES 5 and 7.

Upper holding frame member 48 is provided with a pair of outwardlyextending legs 137 which are pivotally mounted on the same pivot pins126 that pivotally support the elongated side bars 116 supporting thelower holding frame member 46. This common pivot enables the two framemembers 46 and 48 to pivot together as a unit when interconnected, itwill be described below, or to pivot relative to one another, as shownin FIGURE 1. The apertures 137a in the legs 137 through with the pivotpins 126 extend is slightly larger in diameter than the pivot pins 126to achieve a loose fit therewith. Thus both the transfer means 44 andthe upper frame member 48 is permitted to move or tilt slightly withrespect to the turret 97 while retaining a secure connectiontherebetween. The spacing between the apertures 137a and the pivot pins126 may be in the range of about inch to inch.

The endwall 132 of the illustrated upper holding frame members 48furthest from the pivot point of the frame or pivot axis of the framemember 48 is provided with an outwardly extending handle plate 138designed to be grasped by the user for manipulating or moving the framemember 48 relative to the other frame member 48. Also, the member 48 hasa plurality of recesses 139 into which the ends of the projections 50 ofthe lower member 46 are received.

When the two frame members 46 and 48 are separated, the rectangularthermoplastic sheets 34 are supported on the lower holding frame member46. More specifically, the periphery or edge of the sheet 34 lays uponthe annular ledge 112 with the projections 50 of the frame member 46protruding through the apertures 54 of the illustrated sheet. Thisconstruction of the lower holding frame member 46 facilitates the rapidand accurate placement of the sheet within the holding frame memberwhile positive physical or mechanical engagement and support is providedto the sheet along substantially its entire periphery. Again, it shouldbe noted that the projections 50 may be mounted on the upper framemember 48 and the corresponding recesses 139 made in the lower framemember 46.

Upper holding frame member 48 may then be pivoted into position, asshown in FIGURE 2, with the underside of the vertical sidewalls 130 andthe vertical endwalls 132 overlying annular flange 110 of the lowerframe member 26 and also overlying the periphery of the sheet 34 and theprojection 50 to prevent the sheet from being displaced from itsposition upon those projections. Because of this positive physicalinterconnection between the sheet 34 and the projection 50, the pulling,stretching and the like which takes place during the operation of theapparatus will not dislodge the projections from the apertures in thesheet so long as the two frame members are maintained in locked orinterconnected relationship. Further, when the two frame members 46 and48 are in interconnected relationship, a substantially air tight seal iscreated between the interior of the frame and the exterior by virtue ofthe three layer seal between the flange 110, the sidewalls 130 and 132and the thermoplastic sheet 34 inwardly of the rows of apertures 52.This area of seal is generally rectangular following the configurationof the thermoplastic sheet and being essentially a narrow stripextending around the peripheral area of the sheet but spaced inwardly ofthat sheet as determined by the rows of apertures.

Frame members 46 and 48 are held together by the interconnecting means58 which comprise in the illustrated structure a pair of flexible,resilient, detent elements 54 (see FIGURE 7) and a matching pair ofreception or receptacle means 56 on the lower frame member 46.

More specifically, each of the illustrated detent elements 54 is agenerally rectangular flap which extends downwardly from approximatelythe center of the upper edge of the sidewall 132 of the upper framemember 48 and externally thereof. The detent elements 54 extenddownwardly and somewhat outwardly as seen best in FIG- URE 7, and theseelements 54 may be formed integrally with the upper frame member 48 ofthe same resilient, flexible material such as nylon or various otherplastics. One of these detent elements is positioned at either side ofthe frame member 48.

At either side of the lower frame member 26 and extending through aboutthe center of the annular flange or lip 122, just inwardly of thevertical annular lip, flange or wall 123, is an aperture providing thereception or receptacle means 56 which is adapted to receive the detentelement 54.

In the preferred embodiment of the apparatus, the parts are so arrangedin proportion that the elements 54 are flexed inwardly by engaging thevertical annular wall 123 and are then urged into the respectiveapertures 56 incident to the two holding frame members 46 and 48 beingbrought together. The detent elements 54 are thus flexed and maintainedin a tension position which tends to create a resilient, flexiblecoupling or interconnection or interlocking between the two framemembers 46 and 48, allowing them to move together when desired butpermitting readily separating these frames from one another.

The heating means 62 includes a heating element 142 which is securedwithin the housing 36 a short distance below the cradle structure 76 ofthe heating station. The illustrated heating element 142 produces a lowlevel heat output and in addition, to prevent the child user fromburning his hand on the heating element, a panel 143 is wedged in overthe heating element to shield it from direct contact from the outside ofthe apparatus.

The heating means 62 of the illustrated apparatus also includes a pairof electrical leads 144, as seen in FIGURE 13. The leads 144 are securedat their upper end to the heating element 142 at its side closest to endwall 84 and the leads then extend vertically downwardly adjacent to thatend wall 84 and extend outwardly through an aperture provided adjacentthe bottom of wall 84 to connect to a suitable source of electric power(not shown). As an obvious alternative, the structure could be providedwith an internal source of power for the heating element, such as astorage battery. The electrical leads 144 and the connection betweenthem and the heating element 142 are closed into a separate arearelative to the remainder of the interior of the housing 136 by asuitable shield 146 and 147, secured to the housing wall. This is anadded safety feature should the child gain access to the interior of thehousing as by removing the bottom wall of the housing.

The forming station means 20 of the illustrated apparatus include agenerally rectangular plate or platform 70 of slightly smallerdimensions than the rectangular compartment wall 104 and which isreceived within the compartment wall 184 adjacent the upper edges ofthat wall. Thus, while plate 70 fits within the rectangular spacedefined by the wall, there is sufiicient play or space between the edgesof the plate and the wall to permit ready passage of air therebetween.In addition, plate 70 has perforations 71 to permit ready passage of airtherethrough. The plate 70 is supported in the illustrated embodiment ofthe apparatus by vertically extending support pins 150 which areconnected at their upper end to the plate 70 and at their lower end restupon the horizontal upper wall of the turret 97. If desired, the pins150, lnstead of being connected to both plate 70 and wall 100, may befree relative to either plate 70 or wall 100 so that the cplate 70 maybe removed from the apparatus if desire The mold.45 rests atop the plate70 and is shaped to provide the shape of the object 32 to which thethermoplastic sheet 34 will be formed by the operation of theillustrated apparatus 30. While the mold 45 of the illustrated apparatusis not secured to the plate 70, it would be possible that they besecured together or even integrally formed, in which case either theplate 70 itself or the plate 70 and the support pins would be unsecuredto and free to move relative to the turret 97. In this way, a pluralityof different molds, each of which included its own plate 76 could beprovided with the toy apparatus, although there is an obvious materialsaving by providing a single plate 70 as in the preferred embodiment andmerely placing a variety of different molds 45 upon that plate. Theadvantage of having the mold 45 integrally formed or connected to theplate 71) on the other hand is the elimination of any possibility of themold shifting or moving relative to the plate during the operation ofthe apparatus to provide a defective molded object. This problem couldbe dealt with in the case of a separate mold by the use of one or moreinterlocking pins and apertures between the mold 45 and the plate 70.

As illustrated in FIGURES 1-20, the mold 45 consists of an integralstructure in the form of a ship. However, in another embodiment of thepresent invention shown in FIGURES 21-26, the mold 200 is constructed ofa set of interchangeable elements. As illustrated, the mold 290 isadapted to form a plurality of different vehicles by changing theelements thereof. The elements of the mold 269 include a base member 201adapted to position and engage a plurality of vehicle body members. Thebase member 201 has a plate 202 with several apertures 203 therethrough,with ridges 204 surrounding each aperture 293. The apertures 203 areadapted to permit free escape of the gases within the mold 200 duringthe forming process.

Approximately at each corner of the plate 202 in wheel position arewheel lugs 2tl5 extending upwardly from the plate 202. Connecting eachadjoining pair of wheel lugs 255 across the plate 292 are rails 296.Between the rails 2% and extending upwardly from adjacent the frontaperture 203 is a support lug 207. Each of the wheel lugs 205, the rails2116 and the support lug 207 is adapted to support other mold elements.At the front and rear ends of the plate 202 are pin holes 2198 adaptedto receive the pins extending the other mold elements.

Covering the front portion of base member 201 is a hood member 210 whichrests on the front rail 2% and the support lug 207 and is positionedbetween the front wheel lugs 205. The hood member 210 has pins 211extending downwardly from its front portion which pins 211 are receivedin the front pin holes 2118 of the plate 292. Covering the rear portionof the base member 291 is a cap member 215 which rests on the rear rail206, and the hood member 210 and is positioned between the rear wheellugs 205. The cap member 215 has pins 216 extending downwardly from itsrear portion which are received in the rear pin holes 211 of the plate2132. Covering each side of the base member 291 is a side panel 220which is slidably engaged between the hood member 2111 and the capmember 215 and the wheel lugs 2115.

The mold 2% is placed on a plate 70 and the sheet 34 is molded thereoveras set forth elsewhere in this application. As illustrated, the hoodmember 210 used in the mold 200 may be of a variety of shapes, such ashood members 2111a, 2119b and 21%. Similarly, the cap member 215 andside panel member 229 may each be of a variety of shapes, such as 215a,21512 215a, 220a and 22Gb. Also, the mold 229 may be simply a truck mold221 or a panel back member 222. Each form of each of the elements isinterchangeable with all other forms so that a wide variety of vehiclestyles may be produced. For example, in any vehicle any one of the hoodmembers, 210a, 21tlb or 2190 may be used. The mold 295 is preferablymade of an organic plastic material, such as styrene, having a softeningtemperature at least equal to the softening temperature of the sheet 34.Thus, the mold 200 may even have a somewhat lower softening temperaturethan the sheet 34, but because of its large mass compared to the sheet34 it quickly cools the heated sheet 34 when it comes in contacttherewith. Consequently, the mold 295 will not be heated up to itssoftening temperature.

After the sheet 34 has been formed by mold 290 into a vehicle body 223,the vehicle body 223 is cut from the sheet. A separate chassis 225 withaxles 226 inserted therein and wheels 227 pressed onto the ends of theaxles 226 is then used to complete the vehicle assembly. The chassisassembly 228 is attached to the vehicle body 223 by means of anadhesive, such as glue.

The reduced pressure compartment 47 is formed by the verticalrectangular compartment wall 104, the sheet of thermoplastic material34- itself, the upper wall of the turret 97, and the vertical walls and132 of the upper holding frame member 48 which engages with thecompartment wall 104 as shown in cross section in FIG- URE 11. Thecompartment wall 104 if of generally the same size externally as theinternal dimension of the vertical walls 130 and 132 of the upper framemember 48, and the parts are so constructed and arranged and the pivotaxis is so located that when the frame members 46 and 48 are pivoted tothe forming station they will be positioned directly over the wall 104.In the illustrated structure, compartment wall 104 and frame member wall130 are slightly tapered which will tend to give a wedging fit therebetween and provide an effective air seal between the two walls. Also,at this point, it should be noted that as set forth above, not only isthere a loose fit between the turret 97 and both the transfer means 44and the upper frame member 48 but also there is a loose fit between thetransfer means 44 and the lower frame member 45. Such constructioncauses the upper frame member 4-8 to be self-alignment when it is seatedon the turret 97. Thus the necessity of precise alignment of the variousportions of the apparatus is eliminated and there is compensation forthe wear and tear to which the apparatus is normally subjected bychildren. Similarly, such construction causes the upper frame member 48and the lower frame member 46 to become self-aligning with respect toeach other when the upper frame member 48 is seated in the lower framemember 46. Such self-aligning feature per mits the apparatus to tightlyclamp the plastic sheet between the frame members and to obtain anair-tight seal when molding the plastic sheet.

The plate 71 supports the mold 45 upon it, but permits passage of airbetween its edges and the adjacent compartment wall 104 and through itsperforations 71 as noted above. Alternatively, the upper surface ofplate 70, at least adjacent its outer periphery, may be provided with anirregular or uneven surface by scoring corrugating or other means, toprevent a seal being formed between that upper surface and the sheet 34.Such irregular upper surface construction of the plate 70 combined withthe space between the edges of the plate 70 and the adjacent compartmentwall 84, would permit free flow of air between the areas on either sideof the horizontal plate 70.

The means 49 of the illustrated apparatus for reducing pressure includea vertically oriented cylinder 156 which is secured at its upper edge tothe underside of the top wall 191 of the turret 97 and extendsdownwardly into the interior of the housing 36. The cylinder isgenerally centered below the compartment 47 and it is open at its lowerend. Piston means 153 is disposed within the cylinder 156 for verticalreciprocation. The piston means 158 includes a circular piston 160 offlexible, resilient material, such as for example neoprene, which isdisposed to extend generally horizontally across the cylinder 156. Thepiston 16%) includes adownwardly and outwardly extending flange or flap162 adapted to resiliently and yieldingly engage the interior surface ofthe cylinder 156. The piston means 158 further includes a pair ofcircular piston plates 163 of rigid materials, such as metal, one plate163 being disposed above the piston 160 while the other is disposedbelow it to give the piston means 158 the necessary rigidity. The plates153 are of smalled diameter than the cylinder 156 so that they do notengage the cylinder wall, and the annular flap 162 extends beyond theplates 163 to engage the cylinder wall as noted above. A verticallyoriented piston rod 164 is secured at its upper end to the piston 161Dand the piston plate 163 and serves to hold them together in anassembled condition.

The piston means 158 is vertically reciprocated by actuating or linkagemeans which includes an elongated formed rod 172, pivotally mountedwithin the housing 36. The rod 172 has an elongated center section 174and a pair of branch sections 176 and 178 which extend outwardly fromeither end of the center section 174 at generally right angles. Thecenter section 174 extends longitudinally of the apparatus in agenerally horizontal position and is supported on the inside of sidewall82 by a pair of bearings 180 for rotation about the horizontal axis ofthe center section 174. As illustrated, the bearings 180 are made of lowfriction plastic material such as nylon. Preferably, the pivot means 158is biased into an upward position by a spring 175 connected between thebranch section 176 of the linkable means 178 and the housing 36, asillustrated in FIG. 8.

The branch section 176 extends inwardly of the housing 36 and ispivotally connected at its end to the lower end of the piston rod 164.The other branch 178 of the rod 172 extends inwardly of the housing 36and there is provided at its outer end a further longitudinallyextending section 179 which emerges from the housing 36 through anarcuate aperture or slot 182 in end wall 84. A handle 184 is provided onthe ends of section 179. By moving the handle 184 generally up and downin its arcuate path, as limited by the length of the vertical arcuateslot 182, the piston means 158 is caused to reciprocate verticallywithin the cylinder 156. The lower end of the piston rod 164 moves in aslight are comparable to that defined by slot 182, and this action ispermitted by the flexible material from which the piston 160 isconstructed and by the fit of the piston through the annular flap 162with the surrounding cylinder wall 156. Connected between branch section176 and the upper portion of the housing 36 is a coiled spring 175 whichis adapted to bias the piston means 158 upwardly so that it willautomatically return to its raised position when released. Sucharrangement permits the pressure reducing means 49 to be operated solelyby applying force to cause its downstroke.

The pressure reducing means 49 further includes valve means 190. Thevalve means of the illustrated apparatus comprises a valve aperture 192extending through the upper wall 100 of the turret 97 in a locationslightly otf center of the center of the cylinder 156. As seen best inFIGURES and 8, an elongated rectangular valve strip 194 of a flexibleresilient material is secured at either end in a position generallyflush against the underside of wall 100 and is positioned such that theintermediate part of the strip 194 extends across the valve aperture192.

Thus, when the handle 184 is pumped, causing the piston means 158 toreciprocate within the cylinder 156, the

piston means 158, the strip 194 is forced up against the aperture 192 toblock it and trap air in the cylinder 156 above the piston means 158. Asthe piston means 158 is forced upwardly, this trapped air passes betweenthe flexible flange 162 of the piston 160 and the cylinder wall 156.This process is repeated with each stroke of the piston.

This removal of air from the volume above the horizontal wall 100, whichvolume includes compartment 47, above plate 70 by virtue of the abovedescribed construction of plate 50. Thus a low pressure area is createdimmediately beneath the thermoplastic sheet 34 causing it to form aboutthe mold 45.

The thermoplastic sheet 34 of the illustrated apparatus is generallyrectangular in shape and is provided with a plurality of equally spacedsmall circular apertures 52 which extend in a continuous row located aspecific distance from the periphery of the sheet. These apertures 52,as described above, cooperate with the projections 58 of the frameholding means and various modifications and changes of the specificstructure without varying from the spirit and scope of the invention maybe made so long as the projections 50 and the apertures 52 aremaintained in the corresponding or mating relationship. For example, thehorizontal cross-section of the apertures and projections could berectangular, oval or triangular rather than circular, the spacing orpositioning could be varied, the size could obviously be varied and itwould not be necessary that each of the mating pairs of projections andapertures be like the other pairs of projections and apertures. Forexample, by the size, spacing, shape or other variation ofmatiug pairsof projections and apertures means could be provided for guiding orlocating the thermoplastic sheet upon the frame in some particulardesired orientation.

The illustrated sheet 34 shown in FIGURE 15 includes a thin rectangularfilm 64 of thermoplastic material which will readily reduce to asoftened and workable state with the application of relatively low levelheat source. The film 64 should also have whatever characteristics aredesired to be obtained in the formed object 32. In the illustrated sheet34, the metallic layer 66 is secured to the surface of the film 64remote from the surface heated by heating means 62 and will thus producea metalicized appearance to the inner surface of the object 32 formedfrom the sheet. Secured to the upper surface of the metallic layer 66 isa black layer 68 which may be formed by black lacquer or ink or othersuitable material.

Now considering the operation of the toy forming apparatus 30 in furtherdetail, the upper and lower holding frame members 48 and 46 respectivelyshould be separated from one another as shown in FIGURE 1 of thedrawing. The thermoplastic sheet 34 is then placed in the lower holdingframe member 46, its correct location being assisted by the engagementof the projections 50 of the frame member 46 with the apertures 52 andthe periphery of the sheet. The lower holding frame member 46 mayconveniently be positioned at the heating station as in FIGURE 1 duringthe insertion of the sheet although this position is not necessary. Oncethe sheet 34 is properly located in the lower holding frame member 46,the upper holding frame member 48 is releasably locked into position asshown in FIGURE 2 by the manipulation of its handle 138, the detents 54of the upper member 48 being in a resilient pressure fit and extendingthrough the aperture 56 of the lower frame member 48. The sheet 34 isthus securely held in positive physical engagement along substantiallyits entire periphery in the frame holding means 42. In addition, asnoted above, a substantial air seal is provided between the two sides ofthe sheet 34 adjacent its edges.

The thermoplastic sheet is allowed to remain within the frame holdingmeans 42 at the heating station a sufficient time to allow the sheet tosoften and become pliable and workable. It has been found that effectiveresults may be achieved if a temperature of 350 degrees Fahrenheit isapplied to a thermoplastic sheet for about 6 minutes.

After the sheet is sufiiciently softened, the entire assembly of the twoframe members 46 and 48 and the softened sheet 34 are moved by the largehandle 128 to the forming station. As best seen in FIGURE 3, this is apivoting operation wherein the frame members are turned completely over,in the position shown in FIG- URE 3. The pump handle 184 is thenmanipulated up and down to create the reduced pressure immediately belowthe softened sheet 34 as explained in detail above. This will cause thesheet to assume the shape of the mold 45.

The formed sheet is then allowed to cool in this position. It has beenfound that approximately 15 seconds are sufficient for allowing thethermoplastic sheet to fix or set in its new configuration.

The sheet 34 is then removed from the frame holding means 42 byseparating the upper and lower holding frame members 48 and 46. Thisseparation is achieved by pulling apart the two handles 138 and 128respectively,

either before or after the frame holding means 42 is removed from theforming station.

FIGURE 16 illustrates one possible form of object 32 which may beproduced from a thermoplastic sheet by the illustrated formingapparatus, this object 32 having the form of a ship. The excess materialaround the edges of the formed object may be trimmed or cut away. It is,of course, possible to form a great variety of different kind, sizes andtypes of objects on the illustrated apparatus all within the scope ofthe invention.

After the formed sheet has been removed from the frame holding means, afresh sheet 34 may be put into its place and the process repeated.

Thus, a. novel and approved toy forming apparatus is provided by thepreferred embodiment shown in the drawings. This embodiment includes apair of frame members which hold the thermoplastic sheet in positivephysical contact along substantially its entire periphery to prevent anyundesirable deformation or distortion of the sheet incident to theoperation of the apparatus. Further, in the illustrated toy apparatus,improved interlocking means between the two frame members are providedand a novel and improved thermoplastic sheet construction particularlyadapted for use with such a toy forming apparatus is presented. Theillustrated embodiment includes improved heat distributing anddissipating means, and improved means in the combination for providingsubstan tially air-sealed compartment When the pressure may be reducedto cause the formation of the sheet. A number of other advantages andfeatures of the illustrated structure are also noted above in the courseof the description. Thus, a simple and durable yet highly effective toyforming apparatus is provided which will give children long hours ofsafe and enjoyable activity.

Obviously various modifications and changes in addition to the few notedabove in the course of the description may be made without departingfrom the spirit and scope of the present invention. Various features ofthe invention are set forth in the following claims.

What is claimed is:

1. In a toy apparatus for molding an article from a sheet ofthermoplastic material, the improvement comprising: means defining aheater having a generally horizontal heating surface; means defining amold laterally spaced from said heater; support means defining ahorizontal axis disposed between said heater and said mold; work holdingmeans comprising a first open center frame mounted on said support meansfor pivotal movement about said axis between positions where the opencenter thereof overlies said heating surface and said mold, said moldincluding a generally horizontal peripheral edge portion; said workholding means comprising a second open center frame pivotally mounted onsaid axis; said first open center frame being mounted in the open centerof said second frame for limited universal tilting movement therein 14whereby to assure proper alignment of said first frame with saidperipheral edge portion of said mold.

2. A toy apparatus as defined in claim 1 wherein said mold includes agenerally horizontal peripheral edge portion; said open-center framehaving an inner shoulder portion overlying and closely adjacent saidperipheral edge portion when said open center overlies said mold.

3. A toy apparatus as defined in claim 2 wherein said mold comprisesmeans defining an open-topped box-like chamber having upstanding sidewalls, the upper edges of said side walls defining said peripheral edgeportion; an air pervious mold device positioned in said chamber andextending upwardly therein at least to said open top; and manuallyoperable pump means for drawing a vacuum in said chamber.

4. A toy apparatus as defined in claim 3 wherein said mold devicecomprises a perforated plate-like member having an upper surfacesubstantially flush with said peripheral edge portion and a forming moldremovably resting on said upper surface.

5. In a toy apparatus for molding an article from a sheet ofthermoplastic material, the improvement comprising: a support havingmeans thereon defining a horizontal axis; heating means on said support,on one side of said axis, and having a generally horizontal upwardlyfacing, heating surface below the level of said axis; upstanding moldmeans on said support, on the other side of said axis, and above thelevel of said axis; a work holding frame loosely pivoted on said axis;boundary walls on said frame defining an open center thereof andextending laterally of a plane containing said axis; said frame beingswingable over said axis from a first position wherein said open centeroverlies said heating surface with said boundary wall extendingdownwardly from said plane to a second position wherein said boundarywalls embrace said upstanding mold and extend upwardly from said plane;and clamping means on said frame for holding a workpiece across saidopen center and in a plane substantially at the lower edges of saidboundary walls when said frame is in said first position.

References Cited by the Examiner UNITED STATES PATENTS 562,828 6/96House et al 40 13 635,278 10/99 Hart 4013 2,962,758 12/60 Politis 18192,989,780 6/61 Zimmerman 18-19 3,025,566 3/62 Kostur l8-19 3,133,3145/64 Arnould et al 1819 FOREIGN PATENTS 1,091,316 10/60 Germany.

WILLIAM J. STEPHENSON, Primary Examiner.

1. IN A TOY APPARATUS FOR MOLDING AN ARTICLE FROM A SHEET OFTHERMOPLASTIC MATERIAL, THE IMPROVEMENT COMPRISING: MEANS DEFINING AHEATER HAVING A GENERALLY HORIZONTAL HEATING SURFACES; MEANS DEFINING AMOLD LATERALLY SPACED FROM SAID HEATER; SUPPORT MEANS DEFINING A MOLDLATERALLY SPACED FROM SAID HEATER; SUPPORT MEANS DEFINING A HORIZONTALAXIS MEANS COMPRISINF A FIRST OPEN CENTER FRAME MOUNTED ON SAID SUPPORTMEANS FOR PIVOTAL MOVEMENT ABOUT SAID AXIS BETWEEN POSITIONS WHERE THEOPEN CENTER THEREOF OVERLIES SAID HEATING SURFACE AND SAID MOLD, SAIDMOLD INLUDING A GENERALLY HORIZONTAL PERIPHERAL EDGE PORTION; SAID WORKHOLDING MEANS COMPRISING A SECOND OPEN CENTER FRAME PIVOTALLY MOUNTED ONSAID AXIS; SAID FIRST OPEN CENTER FRAME BEING MOUNTED IN THE OPEN CENEROF SAID SECOND FRAME FOR LIMITED UNIVERSAL TILTING MOVEMENT THEREINWHEREBY TO ASSURE PROPER ALIGNMENT OF SAID FIRST FRAME WITH SAIDPERIPHERAL EDGE PORTION OF SAID MOLD.